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A ZENTEK Group initiative

Design for Recycling

The circularity potential of packaging begins not with recycling, but with design. Design for recycling (D4R) ensures that packaging is developed from the outset with a view to being easily recycled at the end of its service life. Whether materials remain in the cycle depends on factors such as material selection, separability, sortability and aspects such as adhesives, labelling and colour choice. By taking design for recycling into account, companies not only meet the minimum standard set out in the German Packaging Act (VerpackG), but also establish a firm foundation for the upcoming EU requirements under the PPWR.

Every piece of packaging counts

From cups to plastic film to beverage cartons, packaging is at the heart of the design for recycling concept. Every decision made during the development process influences whether materials remain in the cycle later on. Discover how design for recycling can work in practice.

Design for recycling –
holistic packaging development

Design for recycling takes account of the entire packaging life cycle, starting in the development stage and including everything from manufacture and use to subsequent recycling. Packaging is designed so that its materials can be easily and fully recovered in existing collection, sorting and recycling processes.
Packaging should ideally be made of a single material (monomaterial) or combinations of materials that can be readily recycled together. Composites that are difficult to separate or problematic should be avoided.
Lids, labels, films or coatings should be easy to remove without the need for additional tools or aids.
Reductions in material usage should be considered at the packaging design stage in order to conserve resources and reduce recycling effort and expense.
Information about the materials used should be clearly indicated from the design stage onwards to facilitate sorting and enable consumers to dispose of the packaging correctly.
At the design stage, preference should be given to light-coloured or transparent plastics, as these are easier to recycle than dark variants.

Myths and facts

More material means better protection and easier recycling

Abbildung 37 % Rezyklate
The amount of material can be reduced with no loss of functionality – using less also improves recyclability.

Coloured or black plastics are just as easy to recycle

Arbeiter bei der Arbeit in einem industriellen Recyclingzentrum
Dark plastics are often not recognised and end up in nonrecyclable waste – light-coloured materials are more recyclable.

Design for recycling is expensive and incurs high costs

Designer entwickelt Produkt
Lower material inputs and higher recyclability reduce costs in the long term and meet legal requirements.

Design for recycling restricts creativity and branding options

verschiedene Arten von Produktverpackungen
Creative, clearly branded designs are also possible using recyclable materials – and encourage your customers to make positive purchasing decisions.

Benefits offered by the Packaging Act’s minimum standard

The minimum standard published annually by Germany’s central packaging registration authority (ZSVR) sets out when packaging is considered recyclable in accordance with the Packaging Act. Design for recycling takes these requirements into account in development and offers clear benefits.

Your packaging is
more recyclable

Cost advantages in system participation

Legal certainty assured through compliance

Preparation for upcoming EU requirements (PPWR)

The new EU regulation (PPWR

Following the minimum standard set out in Germany’s Packaging Act, the next step is now being taken at EU level with the Packaging and Packaging Waste Regulation (PPWR). The new regulation establishes harmonised rules and binding requirements in all member states. The aim is for packaging to not only be functional, but also designed from the outset to be recyclable. Clear specifications will apply from 2030:

Recyclability as the norm

From 2030, all packaging must be designed to be fully recyclable or reusable.

Design for recycling criteria

The European Commission defines uniform requirements for material selection, separability and sortability.
Abbildung verschiedener Verpackungsarten

Recyclability performance grades

Each type of packaging is classified into a grade from A (highest level of recyclability) to E (nonrecyclable).

Market access only from grade C upwards

Packaging with low recyclability (grade D or E, recycling rate below 70%) may no longer be placed on the market.

How D4R relates to the EU Ecodesign Regulation (ESPR)

The new EU Ecodesign for Sustainable Products Regulation (ESPR) has been in force since July 2024 and makes sustainable products the norm in the internal market. For packaging, this means that any business that already meets the minimum standard and implements design for recycling is on track to comply with PPWR and ESPR.

Durable and recyclable

Products must be designed to be durable, repairable and recyclable.

Conserve resources

Companies must conserve resources and reduce their environmental footprint throughout the entire life cycle.

Digital product passports

Digital passports must be introduced for products, making sustainability information accessible from a single source.
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Legal certainty

All processes – from packaging design to volume reporting – are based on current requirements. Companies act in compliance with the rules at all times.
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From dual-system participation to reporting, in addition to planning measures, we also provide operational support until quantifiable results are achieved.
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